Creating a multi-function steering wheel from scratch

shirubaby

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Ever wanted to control your stereo from buttons mounted on the steering wheel? Well here's how...
But first a disclaimer.

WARNING: to follow this advice is to muck around with the steering wheel...and thus with airbags. My advice is dont do it unless you are comfortable with working around airbags.
My steering wheel did not come with an airbag so this was not a problem. Also one of the units I have developed is embedded in the steering wheel.
But if you want to read on then this is what I did (with pics numbered 1 to ?? from left to right).

Objective and preamble:
To mount micro switches around the steering wheel that when pressed will control a JVC stereo.
Functions i wanted on the multi-function steering wheel where:
Volumn up/down,
Search forward/backwards for radio,
Skip track forward/backwards for ipod,
Cycle through equalizer presets
Select music source
Ipod menu up/down

The stereo I have installed in my car is a jvc kd-g421. I guess it will work with most jvc car stereos. The jvc stereo is coupled with an ipod integration kit (£39.99 special offer from Halfords) which means I can remotely control my ipod as well...cool. This kit (ks-pd100) charges the ipod and transfers music through the dock port on the ipod. It also allows control of ipod through the stereo buttons.
The unit also contains, at the back, a 3.5mm stereo jack input to be hooked up to factory fitted multifunction steering wheels and stalks on many cars...and interface devices already exist (made by Autoleads etc.). But what if you dont have factory fitted steering wheel buttons and remote stalks?
My 1989 300ce was one of those cars that had nothing on the steering wheel...or anywhere near.

I knew the JVC stereo took in a set of bit pusles as a pattern (thorugh the 3.5mm stereo jack); and depending on the code transmitted did various things (like vol up/down etc.). To generate a bit pattern i needed a microcontroller and some assembly code.
You can read the original forum thread I participated in to get a better idea of what kind of pulses the jvc needed:
http://www.avforums.com/forums/showthread.php?t=248455&highlight=diy+jvc+remote

Now at the start of my research I could have taken one of 2 directions. I could create a button pod that i could mount on the fixed steering column. This is easier and would require only one microcontroller circuit. However the 300ce steering wheel is quite large and it is difficult to reach round to any column-mounted pod.

The other research direction (potentially more difficult) was to mount the control buttons round the moving steering wheel. Whilst being easier to reach I was faced with the problem that the wheel will move round and any wires passed though the steering wheel will get snagged round the steering shaft. So how do factory fitted steering wheel buttons work? ONe answer, as with the case of BMW, is to spring load the wires so that they stretch when the wheel is turned and retract, to the correct length, when the wheel is returned to the original position. Geez...complicated.
The other answer is metal concentric slip rings which are present in all steering wheels. There are 2 in every steering wheel and are used for the horn. Suffice to say that slip rings and their associated contacts on the other side (of the steering-wheel/steering-column boundry) allow any electrical circuit to stay connected even when the wheel is moving. For each of the buttons on a multi-function steering wheel there will be a slip ring and associated pin-contact.

BUT my merc only had 2 slip rings and they where being used for the horn. How could I add more slip rings? Then my friend John came up with a great idea.

Why not remove the horn, create a microcontroller cicuit (housed within the moving steering wheel) that utilised the slip ring electrical circuit configuration to send bit pulses to the stereo.

But what about the horn...you might ask?
To solve this we use an extra microcontroller circuit, in-line between the 1st microcontroller circuit and the stereo, which will do 2 things:
1. relay the bit pulses (as is) to the stereo
2. recognise a bit pulse unique to the horn function and then energize a relay to sound the horn for a specific period of time - the unique horn pulse will be generated by the 1st microcontroller circuit when the horn is pressed.

Electronic circuit diagram is to follow...

All of this sounds complicated but the diagrams and pictures will help.

What you need:
Basic Knowledge of simple electronics
Simple soldering skills
A pic programmer (ebay buy)
2 pic micontrollers (free samples can be ordered from microchip.com) - a 16F688 for the circuit inside the steering wheel and a 12F629 for the in-line circuit
1x 12v relay
Some resistors (see circuit diagram)
1x NPN transistor
2x 5v voltage regulators
2x cases to house the circuits
2 pieces of veroboard (one for each circuit)
speaker wire for moving bit patterns from the steering wheel to the stereo
3.5mm stereo jack
7 amp wire to interface the relay to the horn wires.
some small core wire to move 5v levels around the circuit board (if necessary)

most of the above can be ordered from rapid electronics, farnell.co.uk or maplins. And should not cost you more than £25

Phew...I'm tired of writing. Will complete the rest. Now I'm off to gather my notes and draw a circuit diagram.
 
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shirubaby

shirubaby

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right I'm back...

I should now explain how I used the slip rings (i failed to mention this in the above post). See attached pic.

On my merc, there are 2 slip rings and associated contacts. The slip rings are actually mounted on the steering wheel and the copper contacts specific to each ring are mounted on the fixed steering column. IF you remove the steering wheel you will see what I mean.

To remove the steering wheel prise open the front panel (WARNING airbag) and look inside the wheel housing..you will see a bolt with a hex patten on it. You need a special socket bit (available from halfords) to remove the bolt. Once the bolt is out the wheel just pulls off the shaft. Hint...make some marking on the wheel and the shaft so you can align them correctly before refitting.

Anyways....back to slip rings...

On my mercedes the outer slip ring will provide 12v when the key is turned to ACC. This is good. The 12v will act as the supply feed for the microcontroller circuit inside the wheel as well as providing power to the horn - In order to do this the 12v supply feed is tapped and routed to the common (COM) pin on the relay (in-line microcontroller circuit)
The inner slip ring orginally connects with the horn. We break this circuit on the column side and use it to send bit patterns to the in-line microcontrller circuit.
The original horn wire is routed to the relay Normally Open (NO) pin (in-line microcontroller circuit).

The ground for the steering wheel circuit comes from the shaft itself. The steering shaft is not connected to the chassis of the car (neg/earth)...but it can be by using a simple spring type piece of metal (see pic..).
 

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shirubaby

shirubaby

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diagramme for steering wheel microcontroller circuit

this is a simple circuit with

. 1 voltage regulator giving out 5v

. some 10kilo ohm resistors acting as pull-ups for certain input ports on the micro. Other inputs have internal pull-up that are enabled.

pictures include the initial circuit layout...a more compact version of the circuit was intalled in my steering wheel
 

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shirubaby

shirubaby

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in-line microcontroller circuit

this circuit is on the side of the steering column.

the bit pattern comes into the circuit from pin 7 and goes out of pin 6 as an exact copy.

the circuit also interprets a 4000usec (micro-seconds) pulse as a 'horn' pattern and sets pin 5 high for 0.5 seconds. The horn will sound for 0.5 seconds as a result.
 

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shirubaby

shirubaby

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picture of my steering wheel creation

work in progress....

notice the microswitched discreetly positioned around the base.

I used a tiny dremel drill bit and drilled 4 holes for each micro switch. I soldered the signal wire and gnd wire to 2 prongs on the switch and treaded the wires through 2 of the hole i made. With a gentle tug of the wires the microswitch embedded itseld in the rubber steering wheel. It was a tight fit...with no wobble...perfect.
 

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shirubaby

shirubaby

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grounding the steering shaft

the steering shaft is not connected to the chassis...and therefore not grounded. IT need to be ground, otherwise the circuit inside the steering column will not have a gnd reference and will be floating. This is not good when you are trying to send 5v bit patterns that reference the ground.


I noticed a place where the steering shaft is only milimeters away from the chassis. I took out a battery holder leaf spring from an old clock and sliced it length-ways to make it thin enough to fit without obstructing the turn signal mechanism. I then shaped it and squeeze it between the moving shaft and the shaft holder (ground). I then held it in place with some aluminium tape.

The sping connector (as I call it) is held in relation to the shaft with the alu tape and moves in relation to the steering shaft holder...

not sure if i made myself clear on this one...perhaps some pics might help.
 

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shirubaby

shirubaby

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Source code for microcontrollers

And finally the source code for the microcontroller

The following link (temporary) contains the source code for the pic16f688 micro that is embedded inside the steering wheel

courier.lboro.ac.uk/jvc/jvc_micro_circuit.asm

The following link (temporary) contains the source code for the pic12f629 micro that is in-line with the 1st micro and the jvc stereo...and installed on the fixed column side of the steering wheel assembly.

courier.lboro.ac.uk/jvc/jvc_micro_inline_circuit.asm

I really hope people find this useful.:rolleyes: OR be inspired to think up other controls (now that you can get gnd and 12v into the steering wheel).

On any of the points made in this thread; I will be happy to explain further. I understand that some people will not be familiar with electronic interfacing and microchip programming, but it's not that hard.

Good luck
Shiru

I'm also figuring out how to interface this setup if the stereo set was changed to a sony one.
 

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shirubaby

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pictures of the final result

From the front and facing the steering wheel the buttons are not noticeable

The last picture is when the front cover is removed.
 

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shirubaby

shirubaby

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AND if you want to discuss any aspect of the project it can be done here:
[THREAD=27081]http://forums.mercedesclub.org.uk/showthread.php?t=27081[/THREAD]

thanks folks
 
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